ProMinent Sigma 2 S2Ca Operating Instructions Manual
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ProMinent Sigma 2 S2Ca Operating Instructions Manual

Diaphragm motor-driven metering pump control
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Operating instructions
Diaphragm Motor-Driven Metering Pump
Sigma/ 2 Control Type S2Ca
Two sets of operating instructions are required for the safe, correct and proper operation of the metering pumps: The
product-specific operating instructions and the "General Operating Instructions for ProMinent
pumps and hydraulic accessories".
Both sets of operating instructions are only valid when read together.
Please carefully read these operating instructions before use! · Do not discard!
The operator shall be liable for any damage caused by installation or operating errors!
Part no. 985894
PK_2_115
Technical changes reserved.
Original Operating Instructions (2006/42/EC)
®
motor-driven metering
BA SI 040 05/11 EN

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Summary of Contents for ProMinent Sigma 2 S2Ca

  • Page 1 Sigma/ 2 Control Type S2Ca PK_2_115 Two sets of operating instructions are required for the safe, correct and proper operation of the metering pumps: The product-specific operating instructions and the "General Operating Instructions for ProMinent ® motor-driven metering pumps and hydraulic accessories".
  • Page 2 ProMinent Dosiertechnik GmbH Im Schuhmachergewann 5-11 69123 Heidelberg Germany Telephone: +49 6221 842-0 Fax: +49 6221 842-617 email: info@prominent.com Internet: www.prominent.com 2354454235, 1, en_GB © 2011...

  • Page 3: Table Of Contents

    Table of contents Table of contents Identity code S2Ca................5 Safety chapter................. 8 Storage, transport and unpacking..........11 Overview of equipment and control elements....... 13 Functional description..............15 5.1 Drive unit................15 5.2 Liquid end................16 5.3 Integral relief valve..............16 5.4 Multi-layer safety diaphragm..........
  • Page 4 Table of contents 12.2.2 Warning Alerts..............63 12.3 All Other Faults..............63 Decommissioning................64 Technical data................66 14.1 Performance data..............66 14.2 Shipping weight..............66 14.3 Wetted materials..............67 14.4 Ambient conditions.............. 67 14.4.1 Ambient temperatures............67 14.4.2 Media temperatures............67 14.4.3 Air humidity..............

  • Page 5: Identity Code S2Ca

    Identity code S2Ca Identity code S2Ca S2Ca Sigma 2, Control Type, Version a Product range Drive type Main power end, diaphragm Type Performance l/h**** 16050 16090 16130 07120 07220 04350 Dosing head material PVDF Stainless steel Seal material PTFE Displacement Multi-layer safety diaphragm with optical break indicator “pump stops”...
  • Page 6 Identity code S2Ca S2Ca Sigma 2, Control Type, Version a Union nut and PVDF hose nozzle Union nut and SS hose nozzle Version With ProMinent ® Logo Without ProMinent ® Logo Electric power supply 1 ph, 100-230 V, ±10 %, 50/60 Hz...
  • Page 7 Identity code S2Ca S2Ca Sigma 2, Control Type, Version a As 1 + message in the event of a manual stop Dosing monitor Input with pulse evaluation Stroke length adjustment Manual Manual + calibration FPM = fluorine rubber * for SST = 16 bar ** Standard with tube nozzle in the bypass Threaded connection on request.

  • Page 8: Safety Chapter

    The general limitations with regard to viscosity limits, chemical resist‐ ance and density must be observed - see also ProMinent resistance www.prominent.com )! list (In the product catalogue or at Any other uses or modifications are prohibited.
  • Page 9 – Take into account the resistance of the material con‐ tacted by the chemical when selecting the feed chemical - refer to the ProMinent ® resistance list in the product www.prominent.com . equipment catalogue or at...
  • Page 10 Customer Service department Customer Service department refers to service technicians, who have received proven training and have been authorised by ProMinent or Pro‐ Maqua to work on the system. Sound pressure level Sound pressure level LpA <...

  • Page 11: Storage, Transport And Unpacking

    Metering pump with mains power cable If necessary, connector kit for hose/pipe connection Product-specific operating instructions with EC Declaration of Con‐ formity and supplementary information CD for ProMinent pump oper‐ ating instructions. As necessary, documents for options and accessories Storage...
  • Page 12 Storage, transport and unpacking Ambient conditions Data Value Unit Minimum storage and transport tempera‐ -10 °C ture Maximum storage and transport tempera‐ +50 °C ture Maximum air humidity * 95 % rel. humidity * non-condensing...

  • Page 13: Overview Of Equipment And Control Elements

    Overview of equipment and control elements Overview of equipment and control elements Overview of equipment P_SI_0068_SW Fig. 1: Overview of equipment S2Ca Drive motor Drive unit Control unit Liquid end Control elements P_SI_0088_SW Fig. 2: Sigma control elements Relief valve Diaphragm rupture sensor (visual)
  • Page 14 Overview of equipment and control elements P_SI_0079_SW Fig. 3: Block diagram Sigma Control 1 Stroke adjustment dial LCD screen Operating indicator (green) Warning indicator (yellow) Fault indicator (red) [key ] [START/STOP] key [P] key [DOWN] key [UP] key P_SI_0078_SW Fig. 4: Block diagram Sigma Control 2 Mains switch "Diaphragm rupture"...

  • Page 15: Functional Description

    Functional description Functional description 5.1 Drive unit The metering pump is an diaphragm pump, the stroke length of which can be adjusted. An electric motor (1) drives the pump. A worm gear (2) steps down its drive rotation A cam (3), in conjunction with the uptake fork (8) converts this into an oscillation movement of the slide rod (4).

  • Page 16: Liquid End

    Functional description 5.2 Liquid end The diaphragm (2) hermetically shuts off the pump volume of the dosing head (4) towards the outside. The suction valve (1) closes as soon as the diaphragm (2) is moved in to the dosing head (4) and the feed chemical flows through the discharge valve (3) out of the dosing head.

  • Page 17: Multi-Layer Safety Diaphragm

    Functional description P_SI_0019 Fig. 8: Integral relief valve Spring, large Ball Rotary dial Spring, small Hose connection 5.4 Multi-layer safety diaphragm The multi-layer safety diaphragm has the same function as the conven‐ tional double diaphragm system with working and safety diaphragms; how‐ ever it also has the advantage that both diaphragms are joined together in a single unit.

  • Page 18: Operating Modes

    “BUS” operating mode (Identity code, control variant: CANopen or PRO‐ FIBUS ® This operating mode provides the option of controlling the pump via a BUS (see “Supplementary instructions for ProMinent® gamma/ L and ProMinent Sigma versions with PROFIBUS ® ".

  • Page 19: Functions

    Functional description 5.6 Functions The following functions can be selected using the SET menu: "Calibrate" function: (Identity code, stroke length adjustment: manual + calibration) The pump can also be operated in the calibrated state in all operating modes. In this case, the corresponding continuous displays can then indicate the metering volume or the capacity directly.

  • Page 20: Function And Fault Indicator

    Functional description 5.8 Function and fault Indicator The operating and fault statuses are indicated by the three LED indicators “Error” identifier on the LCD screen, see also the "Trouble‐ and the shooting" chapter. 5.9 LCD screen “Error” appears and an additional error mes‐ If a fault occurs, the identifier sage.

  • Page 21: Assembly

    Assembly Assembly CAUTION! Danger of material damage The device can be damaged by incorrect or improper storage or transportation! – The unit should only be stored or transported in a well packaged state - preferably in its original packaging. – Only transport the unit when the red gear bleeding plug is pushed in.
  • Page 22 Assembly Space requirement CAUTION! Danger from incorrectly operated or inadequately maintained pumps Danger can arise from a poorly accessible pump due to incorrect operation and poor maintenance. – Ensure that the pump is accessible at all times. – Adhere to the maintenance intervals. Position the pump so that control elements such as the stroke length adjustment knob, the indicating dial A or the oil inspection window are P_MOZ_0018_SW...

  • Page 23: Installation

    Installation Installation CAUTION! Danger of personnel injury and material damage The disregard of technical data during installation may lead to personal injuries or damage to property. – Observe the technical data- refer to chapter "Technical Data" and, where applicable, the operating instructions of the accessories.
  • Page 24 The pump is supplied with PTFE moulded composite seals with a flare, which are used for the pump connec‐ tions. They seal the connections between grooved pump P_SI_0021 valves and the grooved inserts from ProMinent - see Fig. 15: Moulded composite seals with Fig. 15. corrugated insert –...
  • Page 25 Installation CAUTION! Warning of backflow A back pressure valve, spring-loaded injection valve, relief valve, foot valve or a liquid end do not represent absolutely leak-tight closing elements. – For this purpose use a shut-off valve, a solenoid valve or a vacuum breaker. CAUTION! Warning of illegal operation Observe the regulations that apply where the unit is to be...
  • Page 26 Installation CAUTION! Warning of feed chemical spraying around If no relief valve was connected to the overflow line, the feed chemical sprays out of the hose connection as soon as the relief valve opens. – An overflow line must always be connected to the inte‐ gral relief valve and be fed back to the storage tank or - if required by the regulations - into a special storage tank.

  • Page 27: Installation, Electrical

    Installation CAUTION! Warning of unnoticed diaphragm rupture Only above approximately 2 bar system back pressure is a signal generated upon a diaphragm rupture. – Only rely on the diaphragm rupture sensor at back pres‐ sures greater than 2 bar. 7.2 Installation, electrical General safety notes WARNING! Danger of electric shock...
  • Page 28 Installation For technical data see "Technical Data" chapter. Pacing relay (option) Install the cable which originates from the pacing relay - see the figure in the chapter entitled "Overview of equipment and control elements": Cable A, left. The cable polarity is unimportant. Install the power supply cable to the pacing relay PCB - see the figure in the chapter entitled "Overview of equipment and control elements": Cable B, right.
  • Page 29 Installation Fig. 21: Cable conductor assignments To pin VDE cable Contact CSA cable white NO (normally open) white green NC (normally closed) brown C (common) black – As a NC fault indicating relay - the relay closes immedi‐ ately after the power is switched on and opens in the event of a fault.
  • Page 30 Installation As a NC fault indicating relay - the relay closes immedi‐ – ately after the power is switched on and opens in the event of a fault. As a N/O fault indicating relay, the relay closes in the – event of a fault.
  • Page 31 Installation External control Wiring diagram Wiring diagram View of the cable plug from the front Level switch cable Universal control wire (5-core) blue + black: open Pause function: -> Alarm message brown + black: closed -> Pump dosing brown + black: open ->...
  • Page 32 Installation Technical data "external control" Semi-conductor switch elements with a residual voltage of -0.7 V (e.g. transistors in open-collector circuits) or contacts (relays) can be used as input switch elements. P_BE_0014_SW Control type 0 (see identity code) Pin 1 = Pause input (activating func‐ Voltage with open contacts: approx.
  • Page 33 Installation Control type 1 (see identity code) Pin 1 = Pause input (activating func‐ Voltage with open contacts: approx. 5 V tion) Input resistance: 10 kΩ Control: Potential-free contact (approx. 0.5 Semiconductor switch (residual voltage < 0.7 V) 2 = contact input Voltage with open contacts: approx.
  • Page 34 Installation Block diagram Sigma Control Inputs Outputs Pump, inside Empty signal 3 brown / Pause Level Warning 2 blue / Alarm sensor 1 black / GND VDE cable: 2 green / NC (fault alert) 1 brown / 5 V Fault indicating 1 white / NO Stroke 2 white / Cod.
  • Page 35 2 white / Contact External activation 4 brown / GND Pulse frequency, e.g. contact water meter, PLC etc. Function "External Contact" (ProMinent universal control wire) 3 blue / Analog 5-core 2 white / Contact External 1 brown / Pause activation...

  • Page 36: Pump, Power Supply

    Installation 7.2.2 Pump, power supply Install an emergency cut-off switch or include the pump in the emer‐ gency cut-off management of the system. Install the pump cable. Key electrical data can be found on the pump name‐ – plate. 7.2.3 Other units Other units Install the other units according to their supplied documentation.

  • Page 37: Adjustment

    Adjustment Adjustment For supplementary information see "Control elements and key functions" in the chapter "Overview of equipment and control elements" and "Operating/setting overview" in the appendix. The pump control returns to the continuous display, as soon as no key has been pressed for one minute. 8.1 Basic principles of pump adjustment Installation option flashes...

  • Page 38: Checking Adjustable Values

    Adjustment Changing adjustable values [UP] or [DOWN] . Press the arrow keys ð The flashing digit or number counts up or down. Confirming adjustable values Under "change individual digits": confirm each digit by pressing the [P] key. ð Upon confirming the last individual digit, the display simultane‐ ously changes to the next menu option or into a continuous dis‐...

  • Page 39: Operating Mode Selection (Mode Menu)

    Adjustment To match the pump to your process requirements, you must observe the following procedure: “MODE” menu select the operating mode. In the “SET” If necessary make the settings for this operating mode in the menu. MODE MODE menu CODE CODE menu Continuous...

  • Page 40: Operating Mode Settings (Set Menu)

    Adjustment Analog - ANALOG Manual - MANUAL Analog Manual CONTACT Batch CONTACT - CONTACT Batch - BATCH Continuous display B0085 Fig. 29 8.5 Operating mode settings (SET menu) First in the “MODE” menu select the operating mode! Exceptions: Timer and PROFIBUS ®...
  • Page 41 Adjustment Continuous display B0086 Fig. 30 You can select three types of current signal processing: “0 - 20 mA” : – At 0 mA the pump is stationary. – At 20 mA the pump works at the maximum stroke rate. –...
  • Page 42 Adjustment I [mA] B0088 Fig. 32 F1 Stroke rate at which the pump should operate with current I1 F2 Stroke rate at which the pump should operate with current I2 Plot a diagram similar to the one above - with values for (I1, F1) and (I2, F2) –...

  • Page 43: Contact" Operating Mode Settings (Cntct Menu)

    Adjustment “ER” (Error) you can activate error processing for the Fault processing Under menu option “Curve” processing type. For current signals below 3.8 mA, a fault mes‐ sage appears and the pump stops. 8.5.3 "Contact" operating mode settings (CNTCT menu) Alongside those described in more detail in the chapter "Programmable “CNTCT”...
  • Page 44 Adjustment Example Example table Factor Pulse Number of (sequence) strokes (sequence) Step-up 99.99 99.99 1.50 1.50 (1 / 2) 1.25 1.25 (1 / 1 / 1 / Reduction 0.50 0.50 0.50 0.50 0.50 2.5 (3 / 2) (1 / 1) 0.50 1.33 (2 / 1 / 1) (1 / 1 / 1)

  • Page 45: Batch" Operating Mode Settings (Batch Menu)

    Adjustment “Mem” "Memory" function extension You can also activate the "Memory" function extension (identifier “Mem” = memory). When "Memory" is acti‐ appears on the LCD screen; vated, the pump software adds up the remaining strokes , which could not be processed, up to the maximum capacity of the stroke memory of 65,535 strokes.

  • Page 46: Calibrate" Function Settings (Calib Menu)

    Adjustment 8.6.1 “Calibrate” function settings (CALIB menu) Continuous display B0093 Fig. 37 The pump can also be operated in the calibrated state. In this case, the corresponding continuous displays then indicate the metering volume or the capacity directly. The calibration is maintained when the stroke length is altered by up to ±10 scale divisions (for a set stroke length of 40 % this corresponds to a range from 30 % ...

  • Page 47: Auxiliary Frequency" Function Settings (Aux Menu)

    Adjustment Consequence: The corresponding continuous displays indicate the calibrated values. Total number of strokes and total litres are set to "0" by calibrate. The pump is in the STOP state. 8.6.2 “Auxiliary frequency” function settings (AUX menu) Continuous display B0094 Fig.

  • Page 48: Deleting The Total Number Of Strokes Or Total Litres (Clear Window)

    Adjustment In the first menu option, you can set either CODE 1 or CODE 2 (both use the same number). “CODE 1” , to block adjustment mode (① in "Operating / Select adjustment overview" in the appendix). In the next menu option, enter the number you want to use as the code.

  • Page 49: Operation

    Operation Operation This chapter describes all the operating options available to you if the pump control is showing a continuous display - then the display does not [P] key. contain the symbol for the For supplementary information, please read the over‐ –...
  • Page 50 Operation Changing directly changeable variables To change a value, see below, directly in the corresponding continuous [arrow keys] until the [Set] identifier appears. display, press one of the (The delay period has been programmed in to prevent unintentional changing of values.) “CODE 2”...

  • Page 51: Remote Operation

    ® or CAN bus - see chapter "Settings - selecting the operating mode (MODE menu)" and chapter "Operation", in the "Supplementary instruc‐ tions for ProMinent ® gamma/ L and ProMinent ® Sigma versions with PRO‐ FIBUS ® " as well as your system documentation.

  • Page 52: Maintenance

    Place a spare parts kit in stock ready for maintenance work. You can find order numbers in the enclosed "Supplementary information CD for ProMinent pump operating instructions" under "Ordering information" - "Spare parts kits". Third party spare parts for the pumps may lead to problems when pumping.
  • Page 53 Maintenance Standard liquid ends: Interval Maintenance work Personnel After approx. 5,000 oper‐ Change gear oil - refer to "Changing gear oil" in this chapter. Instructed personnel ating hours Quarterly Check the oil level. Quarterly* Check that the metering lines are fixed firmly to the liquid end. Technical personnel Check that the suction valve and discharge valve are correctly seated.
  • Page 54 Maintenance Prerequisites: Gear oil according to the "Ordering information" chapter is available. Start up the pump. Slowly pour gear oil through the vent screw (1) opening until the oil inspection window (3) is half covered. Allow the pump to run for a further 1... 2 minutes Replace the vent screw (1).

  • Page 55: Repairs

    (both in terms of shape and chemical resistance). Use the correct spare part kits. In case of doubt, refer to – the exploded views and ordering information contained in the "Supplementary information CD for ProMinent ® pump operating instructions". Personnel: Technical personnel...
  • Page 56 Repairs Unscrew the valve from the liquid end. Screw the valve cap (5) on its suction side - see diagram. Carefully remove the parts from the valve body (2). Replace the worn parts. Clean the remaining parts. Check all parts. Insert the valve ball (3 and the valve seat (4).

  • Page 57: Replacing The Metering Diaphragm

    – Use only original spare parts. Use the correct spare part kits. In case of doubt, refer to – the exploded views and ordering information contained in the "Supplementary information CD for ProMinent ® pump operating instructions". Personnel: Technical personnel Requirements: If necessary take protective measures.
  • Page 58 Should this not work, remove dirt or swarf out of the thread and screw the diaphragm correctly onto the drive axle this time. ð If this is still unsuccessful, contact ProMinent-ProMaqua cus‐ tomer service. Place the dosing head with the screws onto the diaphragm - the suction connector must be pointing downwards in the pump's fitting position.
  • Page 59 Repairs Checking the condition of the diaphragm rupture sensor If the inside of the diaphragm rupture sensor has become damp or dirt has penetrated it: replace. P_SI_0020_SW Fig. 44: Section through the Sigma diaphragm rupture warning system ("Visual break indicator" version) Working layer (≙...
  • Page 60 Repairs After a successful test, screw the transparent cover onto the dia‐ phragm rupture sensor and then continue at the top by fitting the diaphragm. Electrical diaphragm rupture sensor Press the piston of the diaphragm rupture sensor with a blunt, smooth object into the dosing head (approximately 4 mm) until the monitor triggers alarm.

  • Page 61: Troubleshooting

    Troubleshooting Troubleshooting Safety information WARNING! Warning of hazardous or unknown feed chemical Should a hazardous or unknown feed chemical be used, it may escape from the hydraulic components when working on the pump. – Take appropriate protective measures before working on the pump (protective eyewear, protective gloves, ...).

  • Page 62: Faults With Error Message

    [P] key (reset function). The red LED indicator illuminates, on the dis‐ Fault at the control. Disconnect the pump from the “Error” and “SYSTEM” play, the identifiers mains then reconnect. flash. If the error message reappears, the send the pump into ProMinent.

  • Page 63: Warning Alerts

    Reset the stroke length or “Calib” and the identifier more than ±10 scale divisions from the value at the recalibrate the pump at the flashes. time of the calibration. desired stroke length. 12.3 All Other Faults Please contact the responsible ProMinent branch or representative!

  • Page 64: Decommissioning

    Decommissioning Decommissioning Decommissioning WARNING! Danger of an electric shock When working on the motor or electrical auxiliary equipment, there is a danger of an electric shock. – Before working on the motor, take note of the safety instructions in its operating instructions! –...
  • Page 65 Decommissioning CAUTION! Danger of damage to the device The device can be damaged by incorrect and improper storage or transportation. – Take into account the information in the "Storage, Trans‐ port and Unpacking" chapter if the system is decommis‐ sioned for a temporary period. (Temporary) decommissioning Personnel: Technical personnel...

  • Page 66: Technical Data

    Technical data Technical data 14.1 Performance data S2Ca Type Minimum pump capacity at maximum Max‐ Suction Permis‐ Connector back pressure imum lift sible pri‐ size stroke ming pres‐ rate sure, suction side Strokes/ ml/stroke m WS R"-DN 16050 PVT 11.4 1"...

  • Page 67: Wetted Materials

    Technical data Types Material version Shipping weight 07120 ... 04350 14.3 Wetted materials Material ver‐ Liquid end Suction/dis‐ Seals* / ball Balls Springs Integral relief sion charge con‐ seat valve nector PVDF PVDF PTFE/PTFE Ceramic / Hastelloy C PVDF / FPM glass ** or EPDM Stainless steel...

  • Page 68: Air Humidity

    Technical data 14.4.3 Air humidity Air humidity Data Value Unit Maximum air humidity *: 95 % rel. humidity * non-condensing 14.4.4 Degree of Protection and Safety Requirements Degree of protection Protection against contact and humidity: IP 55 in accordance with IEC 529, EN 60529, DIN VDE 0470 Part 1 Safety requirements Degree of protection: 1 - Mains power connection with protective earth conductor...

  • Page 69: Diaphragm Rupture Sensor

    Technical data Only use the original fuses from ProMinent! It is not sufficient to use a fuse with the above fuse rating. 14.6 Diaphragm rupture sensor b) Reed switch (identity code specification Allocation "Stroke sensor": 2) 1 (white 4.5 V ... 24 V, max. 10 mA...

  • Page 70: Gear Oil

    Technical data 14.8 Gear oil Manufac‐ Name Viscosity Part no. Volume Quantity, turer class required (ISO 3442) Mobil Mobil VG 460 1004542 1.0 l 0.5 l Gear 634 * or comparative gear oil 14.9 Sound pressure level Sound pressure level Sound pressure level LpA <...

  • Page 71: Ec Declaration Of Conformity

    EC Declaration of Conformity EC Declaration of Conformity For pumps without explosion protection: EC Declaration of Conformity ProMinent Dosiertechnik GmbH We hereby declare, Im Schuhmachergewann 5 - 11 D - 69123 Heidelberg that the following designated product complies with the pertinent fundamental safety and health requirements of the EC Directive in terms of its design and construction and in terms of the version marketed by us.

  • Page 72: Decontamination Declaration

    Decontamination declaration Decontamination declaration...

  • Page 73: Operating / Adjustment Overview

    Operating / adjustment overview Operating / adjustment overview Continuous display Stop/start pump = Lock (CODE 1) Change directly changeable variables = Lock (CODE 2) Prime Start batch (only in "Batch" operating mode) Acknowledge errors Check adjustable values P_SI_0040_SW...
  • Page 74 Operating / adjustment overview Calib Calib P_SI_0039_SW...

  • Page 75: Continuous Displays

    Continuous displays Continuous displays Continuous displays Operating mode "Manual" operating Operating mode "Batch" operating Continuous "Analog" 0...20 mA mode "Contact" with mode with memory display memory and transfer factor 5 Stroke rate Capacity Total number of strokes Total litres (metering quantity) "External"...

  • Page 76: Index

    Index Index " Discharge valve............. 16 "Analog" operating mode settings......... 40 Disposal................ 65 "Batch" operating mode settings........45 Dosing head..............16 "Contact" operating mode settings........ 43 Dosing monitor.............. 47 "External control" terminal..........32 Drive motor..............13 "Manual" operating mode settings........ 40 Drive unit..............
  • Page 77 Index Reproducibility............... 66 Namur sensor..............69 Safety chapter..............8 Operating indicator............20 Safety requirements ............. 68 Operating mode..........40, 43, 45 Scope of supply............. 11 Operating modes............. 18, 20 SET menu............... 40, 45 Operating mode selection..........39 Shipping weight............. 66 Operating mode settings..........

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